Download Black Widow Security BW 2800 Service manual

Electrical/EFI Service Manual
ATV and Motorcycle
P/N : 5002401
August 14, 2002
INTRODUCTION
IMPORTANT NOTICE
You must possess significant mechanical knowledge, skills, and tools to perform most of the
procedures found in this document.
This manual is written for Cannondale Motorsports Dealers and qualified service technicians.
This is not a comprehensive shop safety manual and should not be used by anyone who is not
familiar with standard safety practices and service techniques. This manual does include
warnings and cautions (see descriptions above) that if ignored, could result in
SEVERE PERSONAL INJURY to the service technician or significant damage to the vehicle rendering it unsafe to operate. Anyone operating an “unsafe” vehicle can be SERIOUSLY INJURED
OR KILLED.
We have done our best to identify situations where warnings or cautions are needed and will
continue to do so in future publications. But, YOU must always exercise good judgement, and
follow safe shop practices when performing service procedures as described in this manual.
This manual was accurate at the time of publication. Any supplemental information developed
or written after printing may be available on our web site as a “manual supplement.” Service bulletins and technical notes are also published as required. These are also posted on the website.
You may find that the technical terms and part names in this manual differ from published parts
catalogs or microfiche.
ABOUT THE MANUAL
All the procedures in this manual are organized in a numbered (step-by-step) easy to read format with accompanying photographs, line art, torque values and specifications. The numbered steps of a few procedures are likely
to be separate procedures themselves. When this is the case, the numbered step will include a page reference
number.
COMMENTS?
Send your comments to: Cannondale Corporation, Technical Publications, 2 Corporate Drive, Bedford, PA 15522
Or e-mail: [email protected]
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8/14/02
IMPORTANT MANUAL INFORMATION
FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY
OR DEATH.
Information important to your safety is distinguished in this manual by the following notations: \
The safety alert symbol means......
“ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED.”
DANGER
Indicates that DEATH or severe injury WILL result if the
instructions are not followed.
WARNING
Indicates a potential hazard that could result in serious
injury or death.
CAUTION : NOTE:
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
A CAUTION indicates that special precautions must be
taken to avoid damage to the machine.
A NOTE provides helpful information intended to make
maintenance easier or the instructions presented clearer.
4
CONTENTS
Engine Stop Switch (ATV)
Clutch Lever Switch (ATV)
Key Switch - - - - - - - Starter Solenoid - - - - Starter Motor - - - - - - Fuses - - - - - - - - - -
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - 3
Important Notice - - - - - - - - - - - - - - - - - - 3
About the manual - - - - - - - - - - - - - - - - - 3
Comments? - - - - - - - - - - - - - - - - - - - - 3
-
-
-
-
-
-
-
-
-
-
-
-
59
59
59
59
60
60
IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 4
ENGINE MANAGEMENT SYSTEM (EMS) - - - - - - - - - 6
Engine Control Unit (ECU) - - - - - ECU Programming - - - - - - - - - Servicing connectors and couplers - Barometric pressure sensor - - - - Throttle position sensor (TPS) - - - Coolant temperature sensor - - - - Air temperature sensor - - - - - - - Crankshaft position sensor - - - - - Idle Air Control Valve (IACV) - - - - Ignition coil- - - - - - - - - - - - - EMS Power Relay - - - - - - - - - Fuel pump and fuel pressure regulator
Cooling Fan (ATV - - - - - - - - - -
-
-
-
-
-
-
- 6
- 7
- 9
10
10
12
12
13
14
15
15
17
20
CANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL
VERSION 2.0 - - - - - - - - - - - - - - - - - - - - - - - 21
General Information - - - - - - - - - - - - - - - 21
Installation - - - - - - - - - - - - - - - - - - - - 21
In the Windows Explorer, double click the SecurityCode
application. Or, you can access this application by clicking
on Security code.exe through the program group. - - 22
Common Problems- - - - - - - - - - - - - - - - 23
Interpreting Error Messages - - - - - - - - - - - 24
Other Messages - - - - - - - - - - - - - - - - - 25
Communication cable - - - - - - - - - - - - - - 27
Cannondale Diagnostic and Maintenance tool Main Window - - - - - - - - - - - - - - - - - - - - - - - - 28
ECU Operating code - - - - - - - - - - - - - - - 29
Calibrations - - - - - - - - - - - - - - - - - - - 37
ECU Monitor - - - - - - - - - - - - - - - - - - - 39
Reading Fault Codes - - - - - - - - - - - - - - - 40
FAULT TROUBLESHOOTING - - - - - - - - - - - - - - 42
Sensor Supply Voltage - - - System Voltage - - - - - - Fuel Pump - - - - - - - - - Ignition Coil - - - - - - - - Cooling Fan (ATV Only) - - Fuel Injectors - - - - - - - Throttle Position Sensor (TPS)
Air temperature Sensor - - - Coolant Sensor - - - - - - Idle Air Control Valve (IACV) Crankshaft Position Sensor- -
-
-
-
-
-
-
-
-
-
-
42
43
44
45
46
47
50
51
53
55
56
COMPONENT TESTING (NON-EFI)- - - - - - - - - - - - 57
Battery - - - - - - - - - - - - Rectifier /Regulator - - - - - - Flywheel - - - - - - - - - - - Start Button (ATV & Motorcycle)
Engine Stop Button- - - - - - -
-
-
-
-
-
-
-
-
-
57
57
58
58
58
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8/14/02
ENGINE MANAGEMENT SYSTEM
(EMS)
Motorcycle ECUs are located within the subframe.
Engine operation is supported by the management
system consisting of three main types of electrical
components: the ECU, the sensors, and the actuators.
•
The engine control unit (ECU or ECM) precisely
calculates ignition timing and fuel delivery for all
engine speeds and loads (based on the
currently installed calibration file and its
mapping). The ECU is an extremely reliable
component and should be the last component
checked in the event there is a problem with the
fuel injection system.
•
The sensors of the system collect engine
operating information and transmit it to the
ECU.
•
The actuators are devices like the fuel injectors,
fuel pump, fuel pressure regulator, and spark
plug coil, and relays.
3
1
2
1. ECU
2. Air pressure sensor hose (from airbox and fuel pressure
regulator)
3. Internal barometric (air) pressure sensor.
ATV ECUs are located on the electronics tray under
the cowl.
ENGINE CONTROL UNIT (ECU)
4
3
The engine control unit or “ECU” is a kind of computer that calculates ignition timing and fuel delivery
for all engine speeds and loads based on its programming. It is sometimes referred to as the “brain”
of the fuel injection system. This brain calculates fuel
delivery and ignition timing based on information
gathered from vehicle sensors (inputs) and the calibration file loaded at the factory.
1
3
The ECU inputs are the air temperature, coolant,
crankshaft position, throttle position, and barometric
pressure sensors. Information from these sensors
together with the ECU operating code (hex file) and
engine calibration file (map) are used to control the
system actuators (e.g. fuel pump, ignition coil,
injectors, relays, idle air control valve).
1.
2.
3.
4.
NOTE :
In this manual, the engine control unit is referred
to as the “ECU.” It is also sometimes called an
“ECM” or engine control module. Either reference
is OK.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
2
6
ECU
Air pressure sensor hose (from airbox)
Accessories connector
EMS power relay
ECU PROGRAMMING
of the ATV.
The ECU is “programmed” with three types of information. the operating code (also known as the “hex”
file, the engine calibration file (also known as the
“map”), and the vehicle variables or “calibrations.”
Calibrations are stored in the map file but are specific
to the throttle body and injectors installed on the
vehicle.
Any programmed information can be changed.
using the Cannondale Diagnostic and Maintenance
Tool. Refer to "Cannondale Diagnostic and Maintenance Tool Version 2.0" starting on page 21.
The tool is a combination of a specially developed
Windows- based software program and a data cable
used to connect your PC or pocket PC computer to
your vehicle. With the tool, you can read fault codes,
install engine calibration files, set vehicle rpm, and
monitor engine operating parameters.
2
1
3
ECU diagnostic connectors
ATVs and motorcycles have a diagnostic connector to connect the software tool PC to the vehicle.
•
On 2001 and 2002 Motorcycles, the diagnostic
connector is located near the ignition coil on the
top of the cylinder head.
•
On 2003 motorcycles, the diagnostic connector
is located near the main fuse under the seat.
•
On 2001 - 2003 ATV the diagnostic connector is
located near the radiator shroud on the left side
1. Diagnostic connector
2. EMS power relay
3. Main fuse
Reporting system faults
The ECU is capable of reporting system hardware
malfunctions during operation. It reports current
problems and does not store problem “faults” in
memory.
System faults are read from the ECU using the
Cannondale Diagnostic and Maintenance Tool, a
Windows-based PC program enabling communication between a PC and the vehicle ECU. The ECU
does not store intermittent faults; the faults reported
are occurring at the moment when the ECU Fault
Report window is selected in the software tool. A
special communication cable is needed to connect
the vehicle to a PC. Refer to "Cannondale Diagnostic and Maintenance Tool Version 2.0" starting on
page 21.
This manual provides step-by-step fault diagnostic
testing based on the actual fault reported by the
software tool. Refer to "Fault Troubleshooting"
starting on page 42.
7
8/14/02
P1 and P2 Connectors
Pin identification (P1 or P2)
MC1000 ECUs have two main harness connector
sockets.
Use the following illustration for P1 and P2 pin identification.
Remove both main harness connectors from the
ECU when performing pin point tests described in
this manual.
Also, if required, be sure to disconnect any other
devices; see the specific pin point tests.
•
•
H G FE D CBA
2
Connector P1 color is black. It connects to the
black ECU socket.
4
Connector P2 color is grey. It connects to the
grey ECU socket.
1
3
H G FE D CBA
CAUTION : Allow connector rotating latch to draw the
connector into the ECU socket (coupler). Do not
press or force the connector; it should slide
into the socket easily.
Check for contamination and pin condition
before reconnecting.
This photo shows how to identify individual pins in the ECU
harness connectors. Each row is identified by a number 1-4.
Each column is identified by a letter A - H.
Disconnecting the ECU
1. Disconnect the battery.
Lubricate the connector seals with a highquality dielectric grease before reinstalling.
Use a commercially available pin gauge when
performing pin point tests. Ordinary tester
probes can spread pins resulting in loose
connections.
2. Press in the latch locking tab and rotate the latch
in direction (a) until it stops. Pull the connector
from the ECU socket.
1
1
a
1. Latch
2. Locking tab
Reconnecting the ECU
1. Make sure the battery is disconnected.
2. Make sure the main fuse is removed.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
8
3. Align the latch groove and tab on the ECU socket.
Rotate the latch in direction (b) until the latch is
locked by the locking tab. The latch should operate freely with your fingers; do not force it.
Cleaning
1. Wipe the connector or coupler with a clean, lintfree rag and blow off any moisture using
compressed air.
2. Remove corrosion, rust, stains or other foreign
material by using contact cleaner on the terminals.
2
3. Apply a water-displacement chemical on connector seals.
4. Apply a light coat of dielectric grease onto the terminals/pins, and properly connect the halves.
1
Disconnecting
•
Release any locking device first.
•
Do not pull the leads.
1. Latch
2. Tab
Connecting
•
Inspect for bent terminals/pins, damaged cable
terminal/pin joints, water, dirt, or corrosion, and
secure wiring. If a terminal or pin is bent,
carefully straighten it with a thin-blade
screwdriver.
Many electrical problems could be caused by faulty
electrical connectors or couplers. Check for the following conditions before beginning any diagnostics:
•
Before joining or connecting, check for dirt or
corrosion
•
wet terminals/pins
•
•
dirty or corroded terminals/pins
Push male and female ends together squarely
to avoid incorrectly locating or bending the
terminal pins.
•
broken bent
couplers
•
•
terminal pins backing out of the connector or
coupler
Whenever a connector or coupler is
disconnected or checked, be sure to clean it
and apply some dielectric grease before
reconnecting.
•
Make sure the two halves connect positively.
SERVICING CONNECTORS AND
COUPLERS
cable
pins
within
multi-plug
Connector - a single male lead that connects into a
single female lead.
Coupler - multi-pins and usually have some sort of
locking device (e.g., barb, hook, eye) which must be
released before the two halves can be separated.
9
8/14/02
BAROMETRIC PRESSURE SENSOR
THROTTLE POSITION SENSOR (TPS)
The barometric pressure sensor is housed within
the ECU. Air pressure within the airbox is transferred
to the ECU by a narrow hose. Air pressure information is used to adjust the amount of injected fuel to
match the prevailing conditions. The sensor is not
user serviceable. If no external problems are found
with the hose or the hose routing end points, and a
barometric pressure sensor fault persists, the ECU
will have to be replaced.
3
1
2
NOTE :
When performing tests, start by checking the hose
routing from the ECU to the airbox. The routing
may be interconnected with other devices. Be sure
to check all vacuum/pressure routing hoses for
damage.
Dynamic Test - ECU Monitor
1. TPS Sensor
2. Throttle Body
3. Harness connection point
1. To test, determine the barometric pressure at
elevation in the operating area.
2. Read the reported sensor data with the Cannondale Diagnostic and Maintenance Tool. This value
is reported at the “Airbox Pressure (kPa)” field in
the ECU Monitor window. Refer to "ECU Monitor"
starting on page 39.
3. Compare the known value with the one reported
by the software tool. If the comparison of the
actual value and the reported value results in a
wide disparity, and no other faults are present and
engine trouble remains, consider replacing the
ECU.
NOTE :
When comparing the actual barometric pressure
reading and the one reported through the
software, be sure to convert to equivalent units
(kPa).
The throttle position sensor (TPS) is a rotary potentiometer attached to the end of the throttle plate shaft
on the right side of the throttle body.
Fueling requirements are calculated by the ECU for
changing throttle positions.
The fully closed and fully open throttle positions
(interpreted by the minimum and maximum voltage
read through the sensor) are stored as numeric
values in the ECU.
NOTE :
Anytime the throttle body is serviced or the sensor
is removed or replaced, the min/max values must
be re-read into the ECU using the Update
Calibrations window of the tool.
Use the Cannondale Diagnostic and Maintenance
Tool.
Refer to "“Throttle Body Leakage” (also called
Throttle Body Offset) (Input range 0 - 100) The
equivalent amount, in percent, of throttle opening
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
10
required on a “perfect” throttle body to match the
air flow of the vehicle's throttle body at the closed
position. Typical values are from 0.0 to 1.0%"
starting on page 37.
Static Test - Resistance
1
The TPS sensor signal informs the ECU of not only
the relative position of the throttle plate, but also the
speed with which it is being opened or closed. The
engine load is determined by the TPS and engine
speed (rpm). The voltage output from the TPS
increases proportionately as the throttle is opened.
The sensor contains no user serviceable items.
Dynamic Test - ECU Monitor
1. Use the ECU Monitor windows of the Cannondale
Diagnostic and Maintenance Tool and read the
Throttle position (%) field. This field is the percent
the throttle plate is open as translated by the
ECU. With the throttle plate completely closed,
this value should read between 2% to 3%. When
the throttle is fully opened, a normal reading is
97% to 100%. When the idle adjustment is set,
this value should be approximately 3% higher
than the completely closed percent to achieve
rough idle. Fine tuning of the idle adjustment
screw which changes the% percent may be
required
If the Throttle Position (%) field values in the ECU
monitor window are erratic or inconsistent as
described above, the sensor can be tested further
by removing it and reading the resistance values
with an Ohmmeter.
2. Attach a vacuum pump/pressure pump to the
hose end and monitor change. The reading
should increase when increased pressure is
applied. The reading should decrease when vacuum is applied.
NOTE :
Be sure to convert the atmospheric pressure units
displayed in the ECU monitor window with units
displayed with the tools.
1. TPS sensor (shown removed)
1. To test the sensor resistance, remove the sensor
harness connector, remove the mounting bolts,
and remove the sensor from the throttle body.
NOTE :
Removing the sensor from the throttle plate shaft
to measure the resistance is not required.
Removing it and inspecting the housing and shaft
socket for damage can be helpful. Remember that
is the sensor is removed, you will have to reset the
sensor min and max values using the software
tool. Refer to "Setting the throttle position sensor
minimum and maximum values" starting on
page 34.
2. Measure resistance across sensor terminals A
and B.
The resistance should be 1200 ± 240 Ohms.
3. Measure the resistance across sensor terminals
A and C.
- slowly rotate the sensor wheel clockwise and
observe variable resistance. Resistance should
increase smoothly from 0 to 1200 ± 240 Ohms.
CAUTION : Use of high pressure or vacuum when testing
may damage the sensor diaphragm.
11
8/14/02
COOLANT TEMPERATURE SENSOR
1
3. Compare the values. If the two values do not correspond closely, the sensor may be damaged. Go
to the next step.
4. Be sure to replace the radiator cap and start the
engine and allow to reach operating temperature
(60°C). Observe the Engine Temperature (degC)
field in the ECU Monitor window. If the value does
not increase as the engine warms, go to the next
test.
Static Test - Resistance
1. Disconnect the sensor harness connector.
1. Coolant temperature sensor (ATV shown)
The coolant temperature sensor is brown in color
and located on the front of the engine cylinder head.
It is an NTC thermistor.
The ECU measures the current flow through this
thermistor to ground and uses it to determine the
engine coolant temperature. The ECU calculates
fueling to optimize engine performance at all temperatures. It also calculates hot and cold start fueling
requirements.
2. Use an Ohmmeter to measure the sensor resistance between terminals 1 and 2. Refer to "Coolant Sensor Resistance Range" starting on
page 54. If measured resistance is inconsistent at
the tested temperature replace the sensor. If the
sensor is OK, the sensor harness wiring or the
ECU itself may be damaged. Take corrective
action.
AIR TEMPERATURE SENSOR
The intake air temperature sensor is attached to the
airbox with the tip mounted inside the airbox.
It is a NTC thermistor and green in color.
The sensor resistance decreases as the temperature increases.
Dynamic Test - ECU Monitor
1. Starting with a completely cool engine, use the
ECU Monitor window of the Cannondale
Diagnostic and Maintenance Tool to read the
Engine Temperature (degC) field in the ECU
Monitor window. Refer to
"Using the ECU
Monitor" starting on page 39.
2. Open the radiator cap and test the coolant temperature with a thermometer.
Resistance will drop as temperature rises.
The sensor tip is very sensitive to temperature
change.
CAUTION : The tip can be damaged easily; use extra care
when installing or working inside the airbox.
The ECU uses the information from this sensor to
calculate the fuel necessary for a given air temperature.
WARNING
Never open the coolant system when the
engine is hot. Coolant is hot and under
high pressure. It can spray out forcefully
and burn or scald you severely.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
Dynamic Test - ECU Monitor
1. Use the ECU Monitor window
Diagnostic and Maintenance
Engine Temperature (degC)
Monitor window. Refer to
Monitor" starting on page 39.
12
of the Cannondale
Tool to read the
field in the ECU
"Using the ECU
2. Compare the value with a reading taken manually
in the vicinity of the air temperature tip. If the two
values do not correspond closely, the sensor may
be damaged.
Static Test - Resistance
1. Remove the sensor from the airbox by placing an
open-end wrench on the sensor body and turning
it counter-clockwise until it can be removed.
2. Measure the sensor resistance between terminals
1 and 2. Refer to "Air Temperature Sensor Resistance Range" starting on page 52.
If the measured resistance is inconsistent at the
tested temperature, replace the sensor.
If the measured resistance closely matches the
table values, the sensor is OK, the sensor harness wiring or the ECU itself may be damaged.
Take corrective action.
This sensor detects movement of a toothed wheel
that is molded into the flywheel and attached to the
right side of the crankshaft. The wheel has a 36-tooth
pattern. The flywheel teeth are evenly spaced with
the exception of one, triple-length tooth next to one,
triple-length gap. Everytime this tooth/gap passes the
sensor, the ECU interprets it as bottom dead center
(BDC). The ECU uses this information to determine
engine speed and crankshaft position in relation to
the point where fuel is injected and ignition of the air/
fuel mixture occurs.
If the crankshaft position sensor malfunctions, the
engine will not start. If the sensor tip is contaminated
with metallic debris, oils and dirt, or incorrectly
gapped, the engine can run erratically.
If the flywheel is damaged, the sensor may be ok,
but may be reading bad information due to the
resulting change in the indexing between the crankshaft and flywheel teeth. Refer to "Flywheel" starting
on page 58.
NOTE :
Metallic debris or other contaminants on the
sensor tip will affect the sensor.
CRANKSHAFT POSITION SENSOR
1
Inspection points
1. Ensure sensor connection to harness is secure.
2. Check sensor gap: 0.5mm-1.0mm.
3. Check for magnetic debris on sensor tip.
4. Check for damaged flywheel teeth.
a
5. Check flywheel for run-out or play.
2
6. Check flywheel hub for cracking or separation.
The flywheel cover has been removed for this photo to show the
sensor tip.
1.
2.
3.
4.
Crankshaft position sensor
Sensor tip
Flywheel tooth
Gap
Dynamic Test - ECU Monitor
1. Use the ECU monitor window to confirm change
in reported engine rpm.
With the engine off, there should be no reading
displayed at engine rpm field.
SERVICE:
Crankshaft position sensor gap
0.02 - 0.03 in (0.5 -1.0 mm)
The crankshaft position sensor is located in the
generator housing.
13
Crank the engine over and a reading should be
displayed. If no change is observed, the sensor or
harness circuit is faulty. Take corrective action.
8/14/02
Static Test - Resistance
1. Disconnect the sensor harness connector.
2. Use an Ohmmeter to measure the sensor resistance between terminals 1 and 2.
SERVICE:
Crankshaft position sensor
resistance range - 532 TO 588
Ohms
IDLE AIR CONTROL VALVE (IACV)
In a cold engine, the valve opens (arm retracts)
allowing more air to bypass the throttle plate. As the
engine warms up, the valve closes (arm extends)
until the bypass channel through the housing is completely shut at 60°C.
Here are some symptoms of a faulty IACV
•
Hard starting - the valve arm could be stuck
shut. In this case, the extra air needed for cold
starting conditions is not available. Enough air
may be available to start a warm.
•
Engine idles too fast - valve is stuck open.
•
Rough idle - if the valve arm is malfunctioning
Dynamic Test 1 - ECU Monitor
1. Make sure the engine is completely cool.
2. Use the Cannondale Diagnostic and Maintenance
Tool to read current valve stepped position with
the cool engine.
Read the valve position at IACV Stepper Position
field in the ECU Monitor window. Refer to "Using
the ECU Monitor" starting on page 39.
1
NOTE :
Make sure the monitor is in “continuous” mode.
1. Idle Air Control Valve (IACV)
The Idle Air Control Valve (IACV) is an ECU controlled valve mounted on the throttle body.
As soon as the ECU is powered up, this valve
begins to move to the correct position (increasing or
decreasing the available air bypass volume needed
for cold start). The ECU controls the valve arm
depending on engine temperature. The valve arm
moves in “steps” that extend or retract the valve arm
inside the bypass housing.
3. Start the engine and allow to it idle normally.
Observe the IACV Stepper Position and Engine
Temperature (degC) fields. As the engine temperature climbs, the IACV Stepper Position should
increase indicating that the arm is extending and
the bypass channel inside the housing reducing.
At engine operating temperature (60°C) the arm
should be fully extended and the bypass closed.
4. If no change is observed, go to Dynamic Test 2.
Dynamic Test 2 - Confirm arm movement
The arm travels.024mm per step.
1. Make sure the vehicle engine is completely cool
and press the engine stop button to ensure that
the ECU is powered down.
Total travel = 0 to 255 steps
IACV Stepped positions
Fully Open
Fully Closed (at 60°C)
175
205
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
2. Remove the bypass housing from the throttle
body with the IACV valve attached to it.
14
CAUTION : 3. Check the condition of the tip insulator. Make sure
it is not cracked, burned, melted, dried out.
Do not remove the valve from the housing when
performing this test.
4. Make sure the spring is installed with the larger
end facing the coil.
Dynamic Test - Spark Occurrence
3. Disconnect the engine coolant sensor.
4. Reconnect the idle air control valve to the harness.
5. Press the engine start button quickly without turning over the engine. The valve should extend fully.
6. Reconnect the coolant sensor and observe movement of the valve arm; the valve should retract
slightly.
If the valve does not move, replace it with a new
one.
WARNING
An energized ignition coil generates a
high voltage spark capable of jumping to a
ground point. The following procedure will
create a spark that can ignite any available
fuels. You can be seriously injured or killed
in a resulting fire or explosion.
Make sure the work area and vehicle are
free of any gasoline or flammable liquids
(flooded engine, fuel tank, fuel hoses, solvents).
Static Test - Resistance
1. Remove the valve mounting screws and remove
the valve from the bypass housing.
2. Inspect the housing pintel seat and valve pintel
end for damage.
1. Disconnect the ignition coil from the harness
connector.
2. Remove the retaining clip bolt and coil retainer.
3. Lift the ignition coil out of the cylinder head.
3. Measure resistance across sensor terminals (A)
to (D). The resistance should be 53 ± 10% Ohms.
4. Reconnect the harness.
4. Measure resistance across sensor terminals (C)
to (B). The resistance should be 53 ± 10% Ohms.
5. Insert a commercially available spark tester into
the end of the coil. Connect the ground lead of the
indicator to the cylinder head.
IGNITION COIL
6. Turn the ignition switch on and press the engine
start button. If spark is indicated, the coil is OK.
Static Test - Primary Resistance
The ignition coil is a “pencil-type” coil located on top
of the spark plug within the cylinder head.
The ECU controls when the coil is switched on or
off. The coil is switched on to allow sufficient time for
the coil to charge to a level where a spark can be
produced at the spark plug. The coil switches off at
ignition, which is timed for good engine performance.
Inspection Points
1. Check the coil body for damage (e.g., burning,
cracks, discoloration (excessive heat).
1. Measure the resistance between the coil terminal
pins.
EMS POWER RELAY
The EMS power relay supplies the ECU with power
when the vehicle start button is pressed and will
remain locked when the engine is running. The
relay will hold for up to 2 minutes without the engine
running or turning over, then it will drop power to
ECU.
2. Check the coil terminal pins. Make sure they are
in good condition.
15
8/14/02
On motorcycles, if this relay is damaged, the
engine can start but will shut down when the start
button is released.
number 85. There should be continuity
between terminals 30 and 87. If there is not,
the relay is damaged; replace it.
On ATVs, if this relay is damaged or removed, the
engine will run, but damage to a harness diode will
result. When the diode fails, the engine will not run.
5. Use a voltmeter to verify that there is voltage
present at the wiring harness socket
corresponding to relay terminal 87. Do not
start the engine. If there is no voltage present,
check the main fuse. Use the vehicle wiring
diagram to check the circuit. Take corrective
action.
There are no markings on the socket itself;
use the illustration below for identification.
Dynamic Test
1. Remove the relay from its harness socket.
2. Using an ohmmeter, connect the positive probe
(+) onto terminal number 86 and the negative
(-) probe onto terminal number 85. Check the
resistance. The resistance should be 1500 ± 10%
Ohms.
Reverse the meter leads. If the reading is OL (no
continuity), go to the next step.
If the relay is out of specification, replace the relay
with a new one. If the measured resistance is OK,
go to the next step.
DC
12.5 V
"30"
"86"
30
"85"
85
86
"87"
RELAY - P/N 5000411
SOCKET
3. Using an Ohmmeter, connect the positive
probe (+) onto terminal number 30 and the
negative (-) probe onto terminal number 87.
Check the for continuity. There should be no
continuity. If continuity is observed, the relay
is damaged; replace it. If no continuity is
observed, go to the next step.
NOTE :
Wiring diagrams are available on our website.
http://www.cannondale.com/motorsports/tech/
servman.html
4. Connect 12 V (+) battery voltage to the
number 86 terminal and ground terminal
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
87
16
NOTE :
When the ignition switch is turned “ON,” the
installed relay will make an audible “click.”
The fuel pressure regulator maintains the correct
fuel pressure in the fuel rail (hoses and injectors). It
returns fuel to the tank after fuel passes the fuel
injectors. The regulator is connected to the airbox via
a small hose. On ATVs the fuel pressure regulator is
mounted on the main frame on the right side of the
vehicle (front).
FUEL PUMP AND FUEL PRESSURE
REGULATOR
3
2
The fuel pump and regulator maintain fuel supply
and pressure to the injectors. When the engine management system is first “powered-up,” this pump activates for 3 seconds to pressure the fuel system then
turns off again until the engine starts. When the
engine starts, it resumes pumping, providing pressurized fuel to the injectors. The regulator returns
fuel to the fuel tank.
NOTE :
The positive (+) pump terminal is always “hot” even with the ignition switch OFF. This terminal is
connected directly to the positive battery voltage
through the main fuse. The pump is activated by
ECU switching the negative circuit to ground.
Consult the vehicle wiring diagram for more detail.
1
4
Components have been removed for this photo.
1.
2.
3.
4.
Fuel pressure regulator housing
Fuel hose (from injectors)
Fuel hose (return to tank)
Air pressure hose (from airbox)
Dynamic Test - Pump and Regulator
NOTE :
If you suspect a problem with the fuel pump, first
check to see if it runs at all. Do the following:
3
Turn the ignition switch “ON” and listen to the
pump, it should make a “whirring” sound for a few
seconds to pressurize the system - then the pump
will turn off.
Start the engine and allow the vehicle to idle. You
should hear a constant whirring” sound - although
it is more difficult to hear.
1
NOTE :
The pump will turn anytime the start button is
pressed on motorcycles, however, the pump
circuit is different is different on ATVs. If the ECU
has not powered down, the pump will not turn on
unless the clutch lever is pulled in and the start
button is then pressed momentarily.
2
1. Fuel pump
2. Fuel inlet (from tank)
3. Fuel outlet (to injectors)
1. If the fuel pump does not turn on, check the
following:
Pump wiring terminals. Make sure they are clean
17
8/14/02
and the wiring is in good condition. Make sure the
boots are in place.
regulator are OK.
If the fuel pressure reading is low, quickly disconnect and reconnect the fuel tank return line, if the
fuel pressure reading increases when the return
line is disconnected, the regulator is faulty replace
it.
Check for voltage at the pump when the start
button is pressed. Check for any open or short
circuit conditions in the fuel pump circuit. Consult
the vehicle wiring diagram. Take corrective action
if necessary.
Quick connect fuel fittings - Make sure the O-rings
are in good condition.
Damaged O-rings can
result in pressure loss or the introduction of air
into the fuel lines reducing developed fuel
pressure. The fittings have an internal and
external O-ring. External O-rings can be checked
visually. Fuel flow can be restricted or stop is the
internal O-rings are swollen or damaged.
2. Replace the fuel filter to assure adequate fuel flow
to the pump.
CAUTION : Do not perform this test with unfiltered fuel;
severe damage can occur to the pump or fuel
injectors.
If the fuel pressure does not increase, replace the
pump and regulator.
SERVICE:
1. First, use a multi meter to check for battery
voltage to the pump at the (+) fuel pump terminal.
2. Use an Ohmmeter. Connect the positive lead to
main harness connector CN16 pin B. Connect the
negative lead to ground. Have an assistant turn
the ignition switch “ON”. Press the engine start
button and release it.
If there is continuity, the pump harness circuit is
OK.
If there is no continuity, disconnect the ECU and
check for continuity between CN16 pin B and
ECU connector pin P1 H1. There should be continuity. Take corrective action and repeat step 2.
4. Hold a clean rag around the regulator inlet and
loosen the hose clamp to relieve any residual fuel
system pressure.
If no continuity is present between CN16 pin B
and P1 H1 after the circuit is corrected, replace
the ECU (It is not switching the pump circuit to
ground).
5. Install a T-fitting and fuel pressure gauge between
the regulator inlet and hose coming from the
injectors. Make sure the return line attached to
the regulator outlet is connected to the fuel tanktank.
WARNING
Gasoline is extremely flammable and is
explosive. Handle with extreme care!
When inserting a pressure gauge into the
fuel system, make sure all hose connection are secure. Make sure the fuel tank
outlet and inlet lines are connected properly to the tank.
6. Start the engine and read the generated fuel pressure.
If the fuel pressure reading is OK, the pump and
© 2002 Cannondale Corporation - All Rights Reserved
±.25 bar
Dynamic Test - Voltage test
3. Fill fuel tank with the specified fuel as required.
Electrical_EFI Service Manual.fm
Fuel pressure
3.0
18
FUEL INJECTORS
The fuel injectors are positioned as close as possible to the back of the intake valves. The spray
pattern is fixed. The length of time duration that the
injectors stay open is calculated by the ECU using
the calibration file and data received by the various
sensors.
4
3
Dynamic Test - Function
NOTE :
The following procedure is based on the
assumption that there is adequate fuel supply and
pressure is available in the fuel rail.
1
2
1. Check the injector wiring harness connectors.
Make sure they are secure.
2. Check that the battery is fully charged. The sensor and actuators of the system depend on accurate voltage readings to meter the fuel.
Engine shown removed for clarity.
1.
2.
3.
4.
Left fuel injector
Right fuel injector
Fuel inlet (from fuel pump outlet)
Fuel outlet (to pressure regulator)
3. Check the air filter element. If it is dirty or blocked,
this will severely impede air flow and fuel economy.
ATVs and motorcycles utilize a pair of fuel injectors
that operate (inject) simultaneously.
Pressurized fuel flows into the injectors from the
fuel pump. The fuel is delivered into the intake port
when the ECU sends voltage to the injector internal
solenoid. When the solenoid actuates, the pressurized fuel sprays, through the nozzle.
4. Check the airbox and throttle body assemblies for
possible air leaks that would result in a leaning of
the fuel mixture.
5. Use an automotive stethoscope to determine if
each injector is working properly. You should hear
a steady clicking sound that rises and falls with
the engine speed.
If you hear nothing, use a commercially available
noid light to test for voltage present at the harness
connector.
CONNECT
TOP
(FUEL ENTRY)
NOTE :
If you do not have a stethoscope, you can use a
screwdriver against the injector and listen through
the handle.
1
O-RING
Static Test - Resistance
NOZZLE
(FUEL EXIT)
1. Disconnect the injector, and test the resistance of
each injector across the terminals. If the
resistance value is out of specification, replace
the injectors as a pair.
O-RING
1. Fuel injector (left or right)
SERVICE:
Fuel, fuel injector, resistance
11.75 to 12.75 Ohms
2. Install the injector test light (one at a time) into
19
8/14/02
each injector harness connector. Crank the
engine over. If the light flashes evenly on each
connector, voltage is available at the injectors.
3. If the light fails to flash for either injector, check
the fuel injector wiring circuit for continuity. Consult the vehicle’s wiring diagram.
Dynamic Test - Operate
1. Disconnect the main harness connector from the
cooling fan coupler.
WARNING
Spinning fan blades can cause the fan to
jump on the workbench possibly resulting
in severe injury.
If the fan is removed from the vehicle radiator, be sure to secure the cooling fan to
the work bench. And, position the fan so
that the blades can spin freely when energized. Keep your hand clear of the blades
and wear eye protection.
COOLING FAN (ATV
The positive (+) cooling fan terminal is always “hot,”
- even with the ignition switch OFF. This terminal is
connected directly to the positive battery voltage
through the main fuse.
NOTE :
The ECU switches the negative side of the cooling
fan circuit to ground when engine temperature
reaches the ON point. It breaks the ground contact
when the temperature drops to the OFF point. The
ON and OFF points are determined by the ECU
operating code.
2. Connect a 12 V (+) battery voltage source to
the red fan lead. Connect the 12V (-) lead to
the black fan lead. If the fan runs, it is OK.
Check to make sure the airflow is correct;
there is a flow direction indicator on the fan
housing. Airflow should be drawn through
the radiator from the front of the vehicle to the
back. Go to the next step.
Cooling Fan (ECU switching)
ON
OFF
85°C
80°C
If the fan does not operate normally (e.g.,
stops and starts, or spins slowly or not at all),
replace the fan.
3. Set the multi meter to VDC or Vdc (20 volt
range).
Connect the positive meter probe to harness
coupler CN22 pin A.
Connect the negative meter probe to ground.
Battery voltage should be present.
Consult the vehicle wiring diagram for circuit
details.
Static Test - Resistance
1. Disconnect the main harness connector from the
cooling fan coupler.
If battery voltage is not present, check the
main fuse or connections to the battery. If the
main fuse and battery connections are OK,
Check for an open or short circuit in the
cooling fan circuit. Consult the vehicle wiring
diagram. Take corrective action.
2. Measure the resistance between the two fan
leads. The resistance should be less than 1 Ohm;
if it is go to the next test.
If it is more than 1 Ohm, replace the fan.
If the fan circuit is OK, check the coolant
sensor.
If the coolant sensor is OK, replace the ECU.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
20
CANNONDALE DIAGNOSTIC AND
MAINTENANCE TOOL VERSION 2.0
This section of the manual describes how to use
the Cannondale Diagnostic and Maintenance
software tool.
GENERAL INFORMATION
3. Follow the installation screens. When the setup
process is complete, the Cannondale Diagnostic
and Maintenance program group will be installed
and a shortcut to the Cannondale Diagnostic and
Maintenance tool will be placed on the your desktop.
But, before you can use the software, you’ll need
to complete the authorization process by making
a telephone call and typing in an authorization
number.
The Cannondale Diagnostic and Maintenance
Tool, Version 2.0 is a Windows-based software application enabling communication with the vehicle ECU.
Use the tool for:
•
Changing the ECU operating code or “hex” file.
•
Installing a new engine calibration file.
Refer to "Sending a calibration file or “map” to
the ECU - “Changing a map”" starting on
page 34.
•
Receiving the current engine calibration file
from the vehicle ECU to the PC.
•
Set the vehicle throttle body and injector
variables.
•
Monitor
the
parameters.
•
Read system faults.
(vehicle)
ECU
operating
A special interface cable is needed to connect the
PC to the vehicle once the software is installed and
authorized for use.
INSTALLATION
Installing the software
1. Insert the installation CD into the CD drive of your
computer.
Right click on the Windows START button in the
lower left corner of the screen.
Use Windows Explorer, click on the CD drive
containing the Cannondale Dealer Cal software
CD to view the file contents.
2. Double click on the Setup.exe application.
21
8/14/02
In the Windows Explorer, double click the SecurityCode application. Or, you can access this application by clicking
on Security code.exe through the program group.
HE R
E
When the DealerCal window displays (see next illustration), call: Optimum Power Technology at 1-800-727-9520
(Monday through Friday, (9 am to 5 pm EST) to obtain the security code needed to activate the software.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
22
Enter the Serial provided by the service rep in the
DealerCal window. Click Next.
’Device Manager’ Button.
5. Click the ’+’ next to ’Ports’ to expand the available
ports detail. If there is a red ’X’ or a yellow ’!’ in
front of the Communications Port, a problem
exists with your Port Driver. Contact your Computer specialist to resolve the problem. If there is
only a connector icon, note the Communications
Port Name (COM1, COM3, etc.) Run your DealerCal software. Under ’File->Change Port’ change
your Active Port to the above Communications
Port Name. DealerCal will retain this setting.
NOTE :
NOTE: If your computer only has a USB
connection, you must purchase a “USB-to-Serial
adaptor” in order to use the DealerCal software.
COMMON PROBLEMS
Verifying COM port setup
Under Windows 95/98/2000/NT/ME:
Weak vehicle battery
1. Click ’Start’ button and select ’Settings->Control
Panel’.
2. From ’Control Panel’, Double-click ’System’.
3. From ’System Panel’, click ’Device Manager’ or
’Hardware’ tab. If clicking ’Hardware’, click the
’Device Manager’ Button.
4. Click the ’+’ next to ’Ports’ to expand the available
ports detail. If there is a red ’X’ or a yellow ’!’ in
front of the Communications Port, a problem
exists with your Port Driver. Contact your Computer specialist to resolve the problem. If there is
only a connector icon, note the Communications
Port Name (COM1, COM3, etc.) Run your DealerCal software. Under ’File->Change Port’ change
your Active Port to the above Communications
Port Name. DealerCal will retain this setting.
Under Windows XP:
1. Click ’Start’ button and select ’Control Panel’.
2. From ’Control Panel’, Double-click ’Performance
and Maintenance’.
3. From ’Performance and Maintenance’, doubleclick ’System’.
4. From ’System Panel’, click ’Device Manager’ or
’Hardware’ tab. If clicking ’Hardware’, click the
23
Before using the software to communicate with the
vehicle, make sure the battery is fully charged. A low
battery can allow the ECU power relay may drop
power to the ECU which will stop any communication
between the PC and ECU.
EMS not powered-up
In order to use the tool, power to the engine management system must be ON. This is required
because the software tool “communicates” with the
ECU. If the engine management circuits are OFF, the
software cannot receive or transmit any information
to the ECU.
Activating or turning on the engine management
system differs between vehicle types (ATV or Motorcycle). But, in both types, if the vehicle ECU senses
no activity (no engine start or communications
between the PC and ECU) for two minutes, it will
drop the signal voltage to the EMS power relay
shutting down power to itself. If you attempt to send
or receive data from the ECU while it is “powereddown”, the “Failed to Unlock System 125” message
will display.
When this happens, the all power to the engine
management system is shut off until the engine start
button is pressed again.
8/14/02
The vehicle’s lighting or starting electrical systems
are isolated from the EMS power relay supplying the
ECU. Lighting can remain on if the ECU is powereddown. Or, if insufficient battery voltage is present to
hold the EMS relay on, the starter could turn over the
engine, but because the ECU is powered-down, the
engine would not start.
INTERPRETING ERROR MESSAGES
Failed to Unlock System 125
Motorcycles
1. Press the ON/OFF button to ON. This will enable
the engine management system circuits.
2. Next, quickly press and release the engine start
button without starting the engine. The green LED
on the interface cable will light when the engine
management circuits are powered up.
ATVs
1. Turn the ignition switch to the “ON” position, then
switch the Engine RUN/OFF switch to the “RUN”
position.
The “Failed to Unlock System 125” message
means that the Cannondale Diagnostic and Maintenance Tool was not able to communicate with the
vehicle ECU. There can be several causes:
•
Check the interface cable at the vehicle harness
connector. Make sure the vehicle connector
pins are not bent or broken inside the
connector. Make sure the cable connector and
vehicle coupler are locked together.
•
Check the interface cable attachment to the PC.
Make sure the interface cable is plugged in to
the COM port securely.
•
Make sure the right COM port is selected. Refer
to "Verifying COM port setup" starting on
page 23.
•
Make sure the vehicle battery is fully charged.
•
Make sure the vehicle engine management
system is powered-up. See page 23.
•
Click “OK” and start again.
•
If the “Failed to Unlock System” message
displays repeatedly, the vehicle ECU or
2. Quickly press and release the green start button
without starting the engine. The green LED on the
interface cable will light when the engine management circuits are powered up.
NOTE :
On ATVs, after 2 minutes of inactivity (ECU powerdown), the interface cable block green LED will
not go out. It will remain lit as long as the ATV
ignition is in the “ON” position.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
24
interface cable may be damaged.
I/O Error Message
1. You will see this message if the last engine calibration file opened with the software is no longer available such
as: if it was deleted or the CD containing it has been removed from the CD drive.
OTHER MESSAGES
Progress Indicator
Whenever data is being transferred between the vehicle ECU and the PC, a progress indicator displays in the
upper right area of the main screen. Data transfers should take no more than 1 minute. If the progress indicator
freezes for a long time, close the Cannondale Diagnostic and Maintenance Tool software and try again, Make sure
the cables are connected properly and that the vehicle battery is fully charged.
25
8/14/02
Retrying Checksum
Data is transferred between the vehicle and PC in small “packets” or chunks. During the transfer process, checks
are performed by the diagnostic tool (software) to ensure that the data is not damaged during the transfer. Each
small packet is checked during the transfer. If data errors are detected in the packet, the message “Retrying
Checksum...” will display in the progress indicator:
Typically, this is due to electrical “noise” or other interference during the process. The diagnostic tool will keep
trying automatically.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
26
COMMUNICATION CABLE
Connecting the communication cable
Motorcycles and ATVs have a “diagnostic” connector integrated into the main wiring harness. The
communication cable connects the PC to the vehicle
using the connector.
CAUTION : Connect the communication cable with the
vehicle engine management system OFF.
On 2001 and 2002 Motorcycle models, the diagnostic connector is located near the ignition coil at
the top of the cylinder head. Vehicle components
must be removed to access the connector.
On 2003 Motorcycles, the diagnostic connector is
located near the main fuse under the seat.
On 2001 - 2003 ATV, the diagnostic connector is
located near the radiator shroud under the front
fender on the left side of the ATV.
1
2
3
4
1.
2.
3.
4.
Serial connector (PC)
LED
Cable
Connector (vehicle)
NOTE :
Check the diagnostic connector pins for any
bending or damage before connecting to the
vehicle.
27
8/14/02
CANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL MAIN WINDOW
1
8
3
9
4
5
6
7
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
Numeric Cal ID
Description (saved files only - not stored in ECU)
Buttons
Throttle position sensor min and max values (from vehicle)
Throttle Body Leakage (also Throttle Body Offset) (Factory dyno value)
Fuel injector flow rate (Factory dyno value)
Injector offset (Factory dyno value)
Progress indicator
Button to access software version information and Cannondale internet files: http://www.cannondale.com/motorsports/tech/maps/
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
28
Engine Calibration File (“Map”)
Identification
All Cannondale factory authorized engine calibration files are identified by a Numeric Cal ID code.
The Numeric Cal ID number defines the year,
model, and issue sequence of any specific engine
calibration file. The engine calibration Numeric Cal ID
number is displayed in the top left corner of the Cannondale Diagnostic and Maintenance Tool main
window whenever a “map” is opened or received
from the vehicle ECU. The code number also displays at the Numeric Cal ID field within the main
window.
Cannondale vehicles (ATVs and motorcycles) are
loaded at the factory with a model specific authorized
engine calibration file. This file can also be referred
to as the vehicle “map.”
Engine calibration files have the filename extension
“.ccf”
YEAR
Reset every 10 years
(ex. 2002)
MODEL CODE
00 - X440s
01 - X440
02 - C440
03 - E440
30 - Cannibal
31 - Speed
32 - Blaze 440
33 - Moto 440
30202.ccf
Filename extension
All Cannondale authorized
engine calibration files will
have the filename extension
".ccf."
SEQUENCE NUMBER
Assigned sequentially.
New files are
assigned the next available
number 00-99 for the model.
Always check the website
to verify that a calibration
file is authorized for use
in a particular model.
NOTE :
When a calibration file for a model is updated the SEQ number increases. However, due to continual product
evolution, the updated calibration file for the model may not be authorized for use in vehicles produced
previously. Always consult the Cannondale website for the compatibility of calibration files for a specific
vehicle VIN number.
A database of Cannondale authorized engine calibration calibrations files is maintained on the Cannondale website so that service technicians have
ready access to the correct factory authorized calibration files for a particular vehicle VIN.
Go to http://www.cannondale.com/motorsports/tech/maps/.
If “Untitled” is displayed in the top left corner of the
main window, no calibration file has been opened
(from a saved file) or received from the vehicle ECU.
29
ECU OPERATING CODE
The ECU operating code is installed at the factory
before the engine calibration file is loaded.
The operating code also known as the “HEX” file is
like Windows 98 or XP, an “operating system” used in
many PCs. An engine calibration file can be thought
of as a program like Microsoft Excel or Netscape
Navigator, programs which run under Windows.
8/14/02
ATV and Motorcycle operating codes are NOT
interchangeable.
2. In the main window click File - Code Download.
The software tool can load operating code version
updates to the ECU.
The software does not read back the installed operating code currently in the ECU.
To install (update) an operating code
CAUTION : When an operating code is loaded into an ECU
using the software tool, ALL information is
erased from the ECU memory including the
engine calibration file and vehicle variables
(throttle body leakage, fuel injector flow rate,
injector offset). The engine calibration file and
vehicle variables must be reinstalled into the
ECU following the operating code update.
Receive the installed engine calibration file
FIRST. As long as nothing goes wrong with the
PC and the information is retained by the
software tool, the information can be sent to the
ECU right after the operating code update is
finished.
WRITE down the engine calibration file ID
number (Numeric Cal ID), the throttle body
leakage, fuel injector flow rate, and injector
offset before continuing.
1. On ATVs turn the ignition switch ON.
On Motorcycles, disconnect the starter solenoid
so that the engine will not turn over when the start
button is held down in a later step.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
30
3. In the ECU Reprogramming Tool window, select
the operating code file to send.
Have an assistant press and continue to hold the
start button.
Click Download.
The progress indicator will display while the transfer take place.
When the transfer is complete release the start
button. Click Close.
4. Reinstall the correct engine calibration file. Be
sure to update the vehicle variables before sending the file to the ECU.
5. On Motorcycles, be sure to reconnect the starter
solenoid.
31
8/14/02
Opening a SAVED Calibration file
CAUTION : NOTE :
A saved calibration file might be one that you have
received via e-mail, downloaded from the our
website, or one that is stored on a diskette or CD.
This button functions the same way as if you click
File - Open in the top right corner of the main
window.
Check the Numeric Cal ID field in the main
window to make sure the filename selected is
displayed. If not, go back to step 2 and repeat.
Once “opened,” the file is ready for installation
into the vehicle ECU.
CAUTION : Before the saved file is sent to the ECU, be sure
to receive the vehicle variable or they will be
lost. Refer to "Receiving a calibration file
FROM THE ECU “Reading a map and
variables”" starting on page 33.
To open a saved calibration file,
NOTE :
In version 2.0 of the software, when the program
is launched, the last engine calibration file that
was opened is automatically open in the main
window. This feature is useful for servicing many
unit at once, however, be sure to check the engine
calibration file Numeric Cal ID code in the main
window to make sure that the right file is being
used. If not, complete steps 2 -3.
1. In the main window, click on the “OPEN
Calibration File (saved) button.
Use the Windows explorer to locate (browse for)
the saved engine calibration file.
Select the file and click OK.
2. The file is now “loaded” to the main window.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
32
Receiving a calibration file FROM THE
ECU
“Reading a map and variables”
complete” message.
By receiving the engine calibration file or the
vehicle variables from the ECU, the technical can
determine which specific engine calibration file is in
use by the vehicle and what the vehicle specific
variable are included in the data file: throttle min/
max, Throttle body leakage (also known as offset,
fuel injector flow rate, and injector offset).
NOTE :
When you “receive” an engine calibration file, a
copy of the file stored in the vehicle ECU is loaded
in the software tool main window. The vehicle
specific variables or “calibration” are also loaded.
No information is removed or deleted from the
vehicle ECU.
5. Click OK.
The vehicle calibration file has now been
copied to the Cannondale Diagnostic Tool
program. 4-SEND Calibration File (to ECU).
You can select to receive all the calibration file
from the vehicle ECU or just the throttle body and
injector variables or “calibrations.”
In case of PC failure, it is a good idea, whenever a
file is received from the vehicle ECU to write down
the throttle body and injector variables or
“calibrations.”
To receive
1. Connect the interface cable to the PC and
vehicle.
2. Open the Cannondale Diagnostic Tool software
on your PC.
3. Power-up the ECU.
4. Click the RECEIVE Calibration File (from ECU)
button.
After you click the button, the data transfer will
start. While the data is copied from the ECU to the
PC the progress indicator in the upper right of the
menu will display and the LED on the interface
cable block may appear to flicker. The time
required for the transfer could vary. It should take
place within 1 minute. When the entire data transfer process is complete, you will see the “Receive
33
8/14/02
Sending a calibration file or “map” to
the ECU “Changing a map”
You’ll want to pay close attention to what engine
calibration file is actually open before you send
the file to the ECU in the following steps.
Click the OPEN Calibration File (saved) button
to open the Open Calibration File window to
browse for a saved engine calibration file on your
PC. Select the filename and click OPEN.
NOTE :
“Sending” a calibration file transfers the engine
calibration file and vehicle variables currently
open in the Cannondale Diagnostic and
Maintenance Tool main window to the vehicle
ECU.
-- or -Select File-> Open.
Sending will over-write the ECU current engine
calibration file and vehicle variables.
Vehicle variables (throttle min/max, throttle body
leakage (a.k.a Throttle body leakage), fuel injector
flow rate, and injector offset) are over-written only
if the values have been entered through the
Update Calibrations button. If no values are
entered, the vehicle variables stored in the ECU
are used.
If the interface cable is disconnected accidentally
or problems with the PC interrupt the transfer
process, the engine calibration file send process
should be start over from the beginning. Although,
it is possible to quickly reconnect the interface
cable during the transfer process, information can
be lost or damaged.
You should now have an engine calibration file
“open” in the CDMT main window. Confirm that
the correct engine calibration file name is displayed in the top left corner of the CDMT window
and at the Numeric Cal ID field.
3. Next, make sure the vehicle engine management
system is powered-up. When the vehicle is powered-up, the LED on the interface cable block
should be lit.
4. Click the SEND Calibration File (to ECU) button.
If the calibration file open in the main window differs from the one currently stored in the ECU, the
“Cal version different. Do you wish to proceed?”
prompt will display. Click yes to send the file. Click
cancel to exit.
If you click YES, the file that is open in the main
window will be sent to the vehicle ECU. It will
over-write the current calibration file stored in the
ECU. During this process, the vehicle variables
currently stored in the ECU will be retained if the
values have not been entered first using the
Update Calibrations button. If values had been
entered, they will over-write the ECU values during the send process. When the send has been
completed the vehicle ECU will automatically
power itself down. The LED on the interface cable
block will turn off indicating the ECU power is now
off. The calibration file just sent will remain “open”
in the CDMT window until the program is exited or
another calibration file is opened or received.
Do not experiment with calibration files!
Sending unidentified, altered, or third party
calibration files can result in severe damage to
the vehicle or affect the safe operation of the
vehicle. You could be severely injured or killed
in a resulting accident.
Always consult the Cannondale website
(www.cannondale.com) for calibration files
authorized for a specific vehicle identification
number (VIN).
1. To send a calibration file to the vehicle ECU, start
by connecting the interface cable to the computer
and vehicle.
2. Open the Cannondale Diagnostic and Maintenance Tool software on your PC. The CDMT program will automatically open the last engine
calibration file that was open using the program.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
Setting the throttle position sensor
minimum and maximum values
The minimum and maximum values are captured
and recorded into the ECU using the SET Throttle
Position button.
34
The throttle position sensor minimum and
maximum values must be set using the CDMT
anytime the throttle body is serviced (removed,
replaced, installed). It also must be set if the ECU
operating code is updated. Set the throttle position
with the engine off. When the values are set using
the tool, the minimum and maximum value actually
read into the software by the technician are checked
against a range. If any read value is out of range, the
software will report it.
are the values of the current engine calibration
file.
NOTE :
The “TPS Sensor Closed (volts)” and the “TPS
Sensor open (volts)” are displayed in the CDMT
main screen anytime a engine calibration file is
open or received from the ECU.
Next, have an assistant hold the throttle lever fully
open. While the lever is held in the “wide open
throttle” position, click the Read WOT Voltage
button. You should see a change in the numeric
value to the right of the button. Tell your assistant
to release the throttle lever.
1. To set the throttle position, start by making sure
that the idle adjustment screw is backed off
completely. The throttle plate should be
completely shut before you continue.
Again, make sure the throttle plate is completely
closed and click the Read Closed Voltage button.
You should see a change in the numeric value to
the right of the button. The change is the minimum voltage value read from the vehicle TPS
sensor when completely closed. The value can
approach zero, but should be within the typical
range indicated in the window.
Now, both values have been read from the vehicle
TPS sensor. You have two options to consider; go
Double check the throttle bellcrank after backing
the idle adjustment screw off; any slight tension in
the throttle cable can hold the plate open. Confirm
that it is closed all the way by rotating the throttle
bellcrank with your hand - closing it firmly.
NOTE :
When shutting the throttle body plate to set the
minimum value, avoid backing the adjustment
screw out too far that it falls out of the stop plate.
2. Make sure the interface cable is connected to
the computer and vehicle securely.
3. Open the Cannondale Diagnostic
Maintenance Tool software on your PC.
and
4. Power-up the vehicle engine management
system.
5. An engine calibration file must be open in the
CDMT main window to continue. Use the OPEN
Calibration File (saved) or use the RECEIVE
Calibration File (from ECU) button to receive the
calibration file that is currently stored in the vehicle ECU.
6. Click the SET Throttle Position button. The Calibrate Throttle window will display. When the window displays the closed voltage (minimum) and
open voltage (maximum) numeric values shown
35
8/14/02
to the next step to learn more.
Click this butto
to read the TP
sensor minimu
voltage.
These fields
displays the values
that are
"ready to accept"
The fields initially
show a value of the
currently open file.
The values will change
immediately after the
buttons at the left are
clicked.
7. If you click the Accept Values button, the values of
the engine calibration file currently stored in the
CDMT will change to the new ones and immediately the Send Calibrations to the ECU prompt will
display.
again using the Set Throttle Position button.
If you click Cancel, the new values you just read
from the vehicle will be “forgotten” and the values
will revert back to the values of the currently open
engine calibration file; and, the CDMT main window will display.
8. If you click OK, at the Send Calibrations to ECU
prompt, the Select TPS/Inj Calibrations window
will display next. Go to the next step.
If you click Cancel at the Send Calibrations to
ECU prompt, the new values will be updated in
the currently open engine calibration file and
remain until the file is closed, another new engine
calibration file opened or the values are changed
The Send Calibrations to the ECU prompt
9. At the Select TPS/Inj Calibrations window, select
the values to send to the ECU by clicking in the
check boxes. The values displayed in the “From
File” column are the values of the current engine
calibration file open in the CDMT. The values of
the “From ECU” column are the old values.
Click OK to send the values to the ECU. Watch
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
36
the progress indicator. When the send is complete, the Send complete prompt will display, click
OK.
Click Cancel and the “From File” values will not
be sent. They will remain in the currently open
engine calibration file.
CALIBRATIONS
Updating throttle body and fuel injector
calibrations
The Update Calibrations window enables you to
calibrate or “set” the vehicle specific variables which
are included in the engine calibration file data:
Throttle body leakage (offset), fuel injector flow rate,
and injector offset. These variables enable tuning the
installed map to compensate for slight manufacturing variations in each. The numeric values for
these variables are determined when the vehicle is
dyno-tested the factory and loaded to the calibration
file.
The Select TPS/Inj Calibrations window
10. Power-up the vehicle ECU and click on the
MONITOR ECU Parameters button to display
the ECU Monitor window.
Find the “Throttle (%) Open value.” Make
sure the ECU parameters display is in the
Continuous mode.
When a throttle body or fuel injectors are replaced the calibration information are packaged with the
new parts so that service technicians can update the
vehicle.
Adjust the idle adjustment screw so that the
“Throttle (%) Open” value increases by 3. For
example, if the value was 2.3 with the throttle
plate fully closed, turn the adjuster until the
value reads 5.3. If you do not open the throttle
plate the engine may not have enough air to
idle. Opening the throttle plate 3% should be
enough to achieve idle.
The calibration numeric values are part of the
“map” file and displayed in the main window.
NOTE :
When a new engine calibration file “map” is sent to
the ECU the software will prompt to change the
values or use the current values stored in the old
map.
11. Start the engine and allow to idle normally
until the vehicle to reach operating
temperature (70°C). Fine tune the idle setting
as specified for the vehicle.
•
“Throttle Body Leakage” (also called Throttle
Body Offset)
(Input range 0 - 100)
The equivalent amount, in percent, of throttle
opening required on a “perfect” throttle body to
match the air flow of the vehicle's throttle body
37
8/14/02
at the closed position.
Typical values are from 0.0 to 1.0%
•
“Injector Flow Rate”
(Input range 1500 - 3000)
Typical values are from 2300-2800
The fuel injectors’ flow rate, used by the ECU to convert fuel mass in milligrams to injector pulse width in
milliseconds. The lower the flow rate, the longer the ECU has to hold the injector open to deliver a given fuel
mass. For a set of injectors, using a lower flow rate setting will deliver more fuel (richer running), and using a
higher flow rate setting will deliver less fuel (leaner running).
•
“Injector Offset”
(Input range 0.3 - 1.6)
Typical values are from 0.5 to 1.5
The amount of “dead” time of the fuel injector. The fuel injector is an electro-mechanical device, and there is
a delay from the time the electrical signal to open is delivered until the mechanical parts move and allow fuel
to flow. This delay time is added to all pulse widths. In low fuel delivery situations, the injector offset can be
the majority of the pulse width, so the proper value is important to maintain the proper amount of fuel at low
throttle openings. Using a higher injector offset will deliver more fuel (richer running), and using a lower
injector offset will deliver less fuel (leaner running).
To update calibrations, start by connecting the interface cable to the computer and vehicle.
To update calibrations
1. Click the “UPDATE Calibrations” button.
2. Click in the appropriate field in the window and type in the calibration (variable) values.
3. Click “OK” and the typed-in values will display in the CDMT main window. Now, you have to send these values
to the ECU for them to take effect. Click the “SEND Calibration File (to ECU)” button.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
38
ECU MONITOR
1. Open the Cannondale Diagnostic Tool software
on your PC.
2. Power-up the vehicle ECU.
3. Click the MONITOR ECU Parameters button.
The ECU monitor window will be displayed.
Select “Continuous” to view live data.
Select “Hold” to take a snap shot and hold the values displayed.
Click CANCEL to exit and close the monitor.
ECU Parameters (defined)
Monitor selected ECU parameters with the vehicle
engine running or with the vehicle engine off and the
ECU powered-up. It can be operated in “Continuous”
(live) or “Hold” (snap shot) mode. You can start and
run the vehicle engine with the ECU monitor active.
While the monitor window is displayed, constant
communications between the ECU and PC are
occurring - the ECU will not power itself down after 2
minutes. The moment you click CANCEL, the two
minute power-down timing will start if no other communication is attempted.
•
“RPM” - displays the engine rpm
•
“Throttle Position (%)” - displays the
percentage that the throttle plate is open. This
value may not be “0” when fully closed or 100%
when fully open.
•
“Battery Voltage” - displays battery/ system
voltage.
•
“Airbox Temperature (degC)” - air temperature
reading as measured by the airbox air pressure
sensor.
•
“Airbox Pressure (kPa)” - airbox pressure
reading as measured by the ECU sensor.
•
“Engine Temperature “(degC)” - engine
temperature reading as measured by the
coolant temperature sensor.
•
“IACV Stepper Position” step position of the
Idle Air Control Valve (IACV). The ECU moves
or “steps” the valve between 0 - 255 depending
on the current engine and air temperature.
CAUTION : When setting idle speed with the monitor, the
engine must be at operating temperature 70°C.
Using the ECU Monitor
To use the monitor, start by connecting the interface
cable to the computer and vehicle.
39
8/14/02
READING FAULT CODES
To read fault codes
When a fault is reported, consult the fault diagnostic tables in this manual. Refer to "Fault Troubleshooting"
starting on page 42.
CAUTION : Obtain the vehicle’s wiring diagram before attempting any testing.
NOTE :
Most faults reported by the system can be corrected by examining the connector attached to the device or by
tracing circuit for an open or short circuit condition between the ECU connectors and the device connector.
A MIL Lamp fault code (an accessory code) will display on units without ECU interface accessories. The MIL
fault does not indicate a problem with normal engine operations, just the accessories.
Once a fault has been cleared through corrective action, close and reopen the Fault Report window; The ECU
does not store intermittent or one time faults. The Fault Report window will only display current faults available.
1. To read faults, make sure the communication cable is connected correctly.
2. Click the “RECEIVE Fault(s) (From ECU)” button in the main window.
The Fault Report window will display with a list of faults the ECU was encountering when the button was
clicked.
These are “live” faults not stored faults. The GP Control MC1000 ECU programming does not store faults in
memory, therefore the faults displayed in the window are the faults the ECU reports when the Fault Report but-
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
40
ton was pressed. The Fault Report window does
not constantly update fault conditions.
Fault Report window
The Fault Report window sample above was
taken while the Cannondale Diagnostic Tool was
connected to an 2002 X440s motorcycle. This
vehicle does not have a cooling fan. The “Cooling
Fan open fault” will report when the tool is connected to a motorcycle, however, it can be disregarded. Also for the sample fault report above, we
temporarily disconnected the air temperature sensor - notice the “Air temp sensor high fault” that
was reported.
Connect the interface cable to the computer and
vehicle.
41
8/14/02
FAULT TROUBLESHOOTING
Consult the following troubleshooting tables when
diagnosing a fault reported by the Cannondale Diagnostic and Maintenance Tool Fault Report window
function. Refer to "Reading Fault Codes" starting on
page 40.
SENSOR SUPPLY VOLTAGE
Fault Reported
Possible Cause
Action
ECU damaged
Sensor power supply fault
Disconnect ECU and go to Test 1.
wiring fault
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P1 B3
2. Check for harness short
circuit
- P1 B3 to P1 E4
Result
Action
Disconnect throttle position sensor, air
temperature sensor, and coolant sensor,
and go to Test 2.
OK
Faulty
Correct and go to Test 4.
OK
Reconnect ECU and go to Test 3.
Locate short in harness and correct and
go to Test 4.
Short circuit
3. With ignition ‘ON’ check
voltage at:
- P1 B3 at the back of the connector locate wire (70 White)
or at CN3 pin B.
4.5 to 5.5v
Go to Test 4.
Faulty
Replace the ECU, go to Test 4.
4. Reconnect harness, run
engine check for presence of
fault.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
42
SYSTEM VOLTAGE
Fault Reported
Battery voltage low fault
Possible Cause
Wiring/ Stator/ Regulator/
Battery
Action
Check battery voltage at battery;
minimum voltage 12.8v.
Disconnect ECU and go to Test 1.
Battery voltage high fault
Ensure regulator output voltage is within
specified range.
Regulator
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P2 E1
2. With ignition ‘on,’ check
voltage at:
- P2 E1
3. Run engine check for
presence of fault.
Result
Action
OK
Go to Test 2.
Faulty
Correct and go to Test 3.
Same as battery voltage
Go to Test 3.
Less than battery voltage
Locate and correct wiring fault; go to Test
3.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
43
8/14/02
FUEL PUMP
Reported Fault
Possible Cause
Action
Fuel pump short
Damaged fuel pump
(internal short circuit), harness
short circuit, damaged ECU
Fuel pump open
Damaged fuel pump
(internal open circuit) harness
open circuit, harness connector disconnected or terminals at pump loose or disconnected, open circuit to
battery 12V(+).
Component test fuel pump. Refer to
"Fuel Pump" starting on page 44.
Make sure fuel pump connector and fuel
pump terminals are secure.
Verify good main fuse.
Disconnect ECU and go Test 1.
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P1 H1
2.Check for short circuit
between:
- P1 H1 to ground
Result
Action
Disconnect the fuel pump and go to Test
OK
2.
Faulty
Locate and correct and go to Test 2.
Open
Go to Test 3.
Locate and correct wiring fault; go to Test
Shorted
7.
Continuity
3. Check continuity between:
- P1 H1 and CN16 pin B
4. Reconnect ECU, press
e n g i n e s ta r t b u t t o n , w a i t 5
seconds and check for short
circuit between:
- CN16 B to ground
Go to Test 4.
Locate and correct wiring fault; go to Test
5.
Open
Open
Go to Test 5.
Shorted
Replace ECU, go to Test 7.
OK
Go to Test 6.
5. Verify 12V (+) at CN16 pin A
Locate and correct wiring fault; go to Test
6.
None
6. Reconnect the ECU and
fuel pump. Verify that pump runs
briefly (3 seconds) when engine
start button is pressed.
7. Run engine and check for
presence of fault.
OK
Go to Test 7.
Faulty
Replace ECU and go to Test 7.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
44
IGNITION COIL
Fault
Coil short fault
Possible Cause
Damaged ignition coil or
ECU, harness short circuit,
coil connector disconnected
or damaged
Action
Component test ignition coil. Refer to
"Ignition Coil" starting on page 45.
Check ignition coil harness connector is
secure.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
Result
Action
OK
Go to Test 2.
Faulty
Locate and correct and go to Test?.
0.6 Ohms
Disconnect ignition coil and go to Test 3.
Open circuit
Go to Test 4.
Short circuit
Disconnect ignition coil and go to Test 5.
3. Check wire for short circuit
between:
- P2 H1 to ground
Short circuit
Locate and correct wiring fault and go to
Test 7.
Open circuit
Go to Test 7.
4. Check wire continuity
between:
EMS power relay socket terminal 30 and CN8 pin 2.
Continuity
Go to Test 6.
Open circuit
Correct wiring fault and go to Test 7.
1. Check wire and terminal
integrity:
- P2 H1
2. Check resistance value:
Disconnect diagnostic connector CN10, lighting connector
CN26 (Motorcycle only), remove
E M S p o we r r el a y. M e as ur e
between relay socket terminal
30 and P2 H1.
5. Check wiring for short circuit
between:
EMS power relay socket terminal 30 and P2 H1
Locate and correct wiring fault and go to
Test 7.
Short circuit
Open circuit
Go to Test 6.
6. Check ignition coil primary
resistance across coil pins 1 and
2
0.6 Ohms primary
Go to Test 7.
Faulty
Replace coil, go to Test
7. Reconnect ECU, run engine
check for presence of fault.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
45
8/14/02
COOLING FAN (ATV ONLY)
Fault
Possible Cause
Action
Component test the cooling fan. Refer to
"Cooling Fan (ATV Only)" starting on
page 46.
Cooling fan short fault,
Cooling fan open fault
Damaged cooling fan or
ECU, harness short circuit,
fan connector disconnected or
damaged
Component test the coolant sensor.
Refer to "Coolant Sensor" starting on
page 53.
Check that cooling fan harness connector
is secure.
Verify good main fuse.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P2 G1, P2 G2
2. Check wire for short circuit:
- P2 G1 to ground
- P2 G2 to ground
3. Check wire continuity
between:
- P2 G1 and CN22 pin B
Result
Action
OK
Disconnect cooling fan and go to Test 2.
Locate and correct wiring fault and go to
Test 5.
Faulty
OK
Go to Test 3.
Locate and correct wire fault and go to
Test 5.
Short circuit
OK
Go to Test 4.
Open circuit
Correct wiring fault, go to Test 5.
OK
Go to Test 5.
4. Verify 12V(+) at CN22 pin A
Locate and correct wiring fault, go to Test
6.
None
5. Reconnect the cooling fan
and ECU and verify proper fan
operation (on at 85°C, off at
80°C cool ant te mperatur e).
Verify correct airflow.
7. Run engine and check for
presence of fault.
OK
Done
Faulty
Replace ECU and go to Test 7.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
46
FUEL INJECTORS
Fault
Injector A short fault (left)
Injector B short fault (right)
Injector A open fault (left)
Possible Cause
Action
Damaged injector or ECU,
harness short circuit
- flooding indicates short
circuit
Component test the injector. Refer to
"Fuel Injectors" starting on page 19.
Damaged injector, injector
connector disconnected or
damaged, harness open
circuit
Check that injector harness connector is
secure.
Disconnect ECU and go to Test 1.
Injector B open fault (right)
- misfire indicates open
circuit
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P1 H2
Result
Action
OK
Go to Test 2.
Locate and correct wiring fault and go to
Test 7.
Faulty
- P1 H3
2. Check resistance value:
Motorcycle
Disconnect diagnostic connector
CN10, lighting connector CN26,
r e m o v e E M S p o w e r r e l a y.
Measure between relay socket
terminal 30 and:
12.25
2°C
± 0.50 Ohms at 20 ±
Open circuit
Disconnect relevant injector and go to
Test 3.
Go to Test 4.
- P1 H2 (Left injector)
- P1 H3 (Right injector)
ATV
Disconnect the ignition coil,
diagnostic connector CN10,
switch engine stop button to
OFF position. Measure between
P2 E1and:
Disconnect relevant injector and go to
Test 5.
Short circuit
- P1 H2 (Left injector)
- P1 H3 (Right injector)
47
8/14/02
FUEL INJECTORS
3. Check wire for short circuit
OK
Go to Test 7.
- P1 H2 to ground
Locate and correct wire fault and go to
Test 7.
Short circuit
- P1 H3 to ground
4. Check wire continuity:
Continuity
Go to Test 6.
Motorcycle
Disconnect diagnostic connector
CN10, lighting connector CN26,
r e m o v e E M S p o w e r r e l a y.
Measure between relay socket
terminal 30 and:
- relevant injector pin 1
- P1 H3 to CN6 pin 2 (Right
injector)
- P1 H2 to CN7 pin 2 (Left
injector)
Locate and correct wire fault and go to
Test 7.
Open circuit
ATV
Disconnect the ignition coil,
diagnostic connector CN10,
switch engine stop button to
OFF position. Measure between
P2 E1and:
- relevant injector pin 1
- P1 H3 to CN6 pin 2 (Right
injector)
- P1 H2 to CN7 pin 2 (Left
injector)
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
48
FUEL INJECTORS
5. Check short circuit:
OK
Go to Test 6.
Motorcycle
Disconnect diagnostic connector
CN10, lighting connector CN26,
r e m o v e E M S p o w e r r e l a y.
Measure between relay socket
terminal 30 and:
- P1 H3
- P1 H2
Locate and correct wiring fault proceed to
Test 7.
Short circuit
ATV
Disconnect the ignition coil,
diagnostic connector CN10,
switch engine stop button to
OFF position. Measure between
P2 E1and:
- P1 H3
- P1 H2
6. Check injector resistance:
- relevant injector across terminals 1 to 2
7. Run engine and check for
presence of fault.
12.25
2°C
± 0.50 Ohms at 20 ±
Go to Test 7.
Faulty
Replace injector go to Test 7.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
49
8/14/02
THROTTLE POSITION SENSOR (TPS)
Fault
Throttle position sensor high
fault
Throttle position sensor low
fault
Possible Cause
Action
Component test the TPS sensor.
D a m a g e d T P S s e n s o r,
ECU, harness short or open
circuit, TPS sensor connector
disconnected or damaged
Check that sensor harness connector is
secure.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
Result
Action
OK
Disconnect TPS sensor and go to Test 2.
- P1 B3
- P1 E3
Locate and correct wiring fault and go to
Test 5.
Faulty
- P1 B4
2. Check for short circuit
between:
- P1 E3 to ground
3. Check cable continuity:
OK
Go to Test 3.
Locate and correct wiring fault and go to
Test 5.
Short circuit
OK
Go to Test 4.
- P1 E4 to CN3 pin A
- P1 E3 to CN3 pin C
Open circuit
Locate and correct wiring fault and go to
Test 5.
OK
Replace throttle position sensor, go to
Test 5.
Short circuit
Locate and correct wiring fault and go to
Test 5.
- P1 B3 to CN3 pin B
4. Check cable for short circuit:
- P1 E3 to P1 B3
- P1 E3 to P1 E4
5. Reconnect harness, run
engine and check for presence
of fault.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
50
AIR TEMPERATURE SENSOR
Fault
Air temp sensor high fault
Air temp sensor low fault
Possible Cause
Damaged air temperature
sensor, ECU, harness short or
open circuit, sensor connector disconnected or
damaged
Action
Component test the air temperature
sensor.
Check that sensor harness connector is
secure.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P1 D1
Result
Action
OK
Disconnect TPS sensor and go to Test 2.
Faulty
Locate and correct wiring fault and go to
Test 7.
OK
Disconnect temperature sensor and go to
Test 6.
- P1 E4
2. Check resistance value:
- P1 D1 to P1 E4
(verify value at temperature
tested; see table)
3. Check wire continuity:
Open circuit
Go to Test 3.
Disconnect temperature sensor and go to
Test 4.
Short circuit
OK
Go to Test 5.
- P1 D1 to CN5 pin 2
Locate and correct wiring fault and go to
Test 7.
Open circuit
- P1 E4 to CN5 pin 1
4. Check for wire short circuit:
OK
Go to Test 5.
- P1 D1 to P1 E4
Short circuit
5. Check sensor resistance:
OK
Go to Test 7.
Faulty
Replace sensor, go to Test 7.
6. Check wire for short circuit”
OK
Go to Test 7.
- P1 D1 to ground
Short circuit
Locate and correct wiring fault and go to
Test 7.
- CN5 pin 1 to pin 2
(verify value at temperature
tested; see table)
7. Reconnect harness, run
engine and check for presence
of fault.
Locate and correct wiring fault and go to
Test 7.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
51
8/14/02
AIR TEMPERATURE SENSOR
Circuit Diagram
Air Temperature Sensor Resistance Range
Resistance
(ohms)
15071
11739
9215
7290
5808
4659
3763
3058
2500
2056
Temp.
(deg. C)
Temp.
(deg. F)
-20
-15
-10
-5
0
5
10
15
20
25
-4
5
14
23
32
41
50
59
68
77
Resistance
(ohms)
1700
1414
1181
992
837
710
604
517
444
382
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
Temp.
(deg. C)
Temp.
(deg. F)
30
35
40
45
50
55
60
65
70
75
86
95
104
113
122
131
140
149
158
167
52
Resistance
(ohms)
331
287
250
219
192
169
149
132
118
N/A
Temp.
(deg. C)
80
85
90
95
100
105
110
115
120
N/A
Temp.
(deg. F)
176
185
194
203
212
221
230
239
248
N/A
COOLANT SENSOR
Fault Reported
Engine temp sensor high fault
Engine temp sensor hi fault
Possible Cause
Damaged coolant temperature sensor, ECU, harness
short or open circuit, sensor
connector disconnected or
damaged
Action
Component test the coolant temperature
sensor. Refer to "Coolant Sensor" starting
on page 53.
Check that sensor harness connector is
secure.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P1 B2
- P1 E4
2. Check resistance value:
- P1 B2 to P1 E4
(verify value at temperature
tested; see table)
Result
Action
OK
Go to Test 2.
Faulty
Locate and correct wiring fault and go to
Test 7.
OK
Disconnect temperature sensor and go to
Test 6.
Open circuit
Go to Test 3.
Disconnect temperature sensor and go to
Test 4.
Short circuit
3. Check wire continuity:
- P1 B2 to CN4 pin 2
- P1 E4 to CN4 pin 1
OK
Go to Test 5.
Locate and correct wiring fault and go to
Test 7.
Open circuit
OK
4. Check for wire short circuit:
- P1 B2 to P1 E4
5. Check sensor resistance:
- CN4 pin 1 to pin 2
(verify value at temperature
tested; see table)
6. Check wire for short circuit”
- P1 B2 to ground
7. Reconnect harness, run
engine and check for presence
of fault.
Go to Test 5.
Locate and correct wiring fault and go to
Test 7.
Short circuit
OK
Go to Test 7.
Faulty
Replace sensor, go to Test 7.
OK
Go to Test 7.
Locate and correct wiring fault and go to
Test 7.
Short circuit
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
53
8/14/02
Coolant Sensor Resistance Range
Resistance
(ohms)
45313
34281
26114
20003
15462
12002
9397
7415
5896
4712
3792
3069
Temp.
(deg. C)
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
Temp.
(deg. F)
-40
-31
-22
-13
-4
5
14
23
32
41
50
59
Resistance
(ohms)
2500
2057
1707
1412
1175
988
834
703
595
508
436
374
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
Temp.
(deg. C)
20
25
30
35
40
45
50
55
60
65
70
75
Temp.
(deg. F)
68
77
86
95
104
113
122
131
140
149
158
167
54
Resistance
(ohms)
322
280
243
213
187
164
144
127
113
100
89
N/A
Temp.
(deg. C)
80
85
90
95
100
105
110
115
120
125
130
N/A
Temp.
(deg. F)
176
185
194
203
212
221
230
239
248
257
266
N/A
IDLE AIR CONTROL VALVE (IACV)
Fault Reported
Stepper motor fault
Possible Cause
Damaged idle air control
valve, ECU, harness short or
open circuit, IACV connector
disconnected or damaged
Action
Component test the IACV. Refer to "Idle
Air Control Valve (IACV)" starting on
page 55.
Check that harness connector is secure.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
1. Check wire and terminal
integrity:
- P1 E1
- P1 E2
- P1 F1
- P1 F2
Result
Action
OK
Go to Test 2.
Locate and correct wiring fault and go to
Test 5.
Faulty
53 ± 10% Ohms
Disconnect the IAVC and go to Test 3.
Open circuit
Go to Test 4.
Short circuit
Disconnect IACV and go to Test 5.
3. Check cable for short circuit:
- P1 E1 to ground
- P1 E2 to ground
- P1 F1 to ground
- P1 F2 to ground
OK
Go to Test 7.
4. Check cable continuity:
- P1 E1 to CN25 pin A
- P1 E2 to CN25 pin B
- P1 F1 to CN25 pin C
- P1 F2 to CN25 pin D
OK
2. Check resistance:
- P1 E1 to P1 F1
- P1 E2 to P1 F2
5. Check cable for short circuit:
- P1 E1 to P1 F1
- P1 E2 to P1 F2
Locate and correct wiring fault and go to
Test 7.
Short circuit
Go to Test 6.
Locate and correct wiring fault and go to
Test 7.
Open circuit
OK
Go to Test 6.
Locate and correct wiring fault and go to
Test 7.
Short circuit
Check IACV resistance:
- IACV pin A to pin D
- IACV pin B to pin C
53 ± 10%
Go to Test 7.
Faulty
Replace IACV, go to Test 7.
7. Reconnect harness, run
engine and check for presence
of fault.
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Circuit Diagram
55
8/14/02
CRANKSHAFT POSITION SENSOR
Fault Reported
Possible Cause
Action
Check that harness connector is secure.
Crank tooth sync fault
Damaged or contaminated
crankshaft position sensor,
damaged ECU, harness short
or open circuit, IACV connector disconnected or
damaged
Check sensor air gap: 0.5 to 1.0 mm
Check for damaged flywheel teeth.
Check flywheel runout or play.
Disconnect ECU and go to Test 1.
Pinpoint Tests
Test
Result
Action
1. Check wire and terminal
integrity:
- P1 A1
- P1 B1
OK
Disconnect sensor and go to Test 2.
2. Check cable for short circuit:
- P1 A1 to ground
- P1 B1 to ground
OK
3. Check cable continuity:
- P1 A1 to CN2 pin 2
- P1 B1 to CN2 pin 1
4. Check cable for short circuit:
- P1 E1 to P1 F1
- P1 E2 to P1 F2
5. Check cable continuity:
- Sensor cable screen to (frame)
ground
6. Check sensor resistance:
Sensor pin 1 to pin 2
7. Check crank toothed wheel
- Damaged teeth
- Magnetic debris contamination
8. Reconnect harness, run
engine and check for presence
of fault.
Locate and correct wiring fault and go to
Test 8.
Faulty
Go to Test 3.
Locate and correct wiring fault and go to
Test 8.
Short circuit
OK
Go to Test 4.
Locate and correct wiring fault and go to
Test 8.
Open circuit
OK
Go to Test 6.
Locate and correct wiring fault and go to
Test 8.
Short circuit
OK
Go to Test 7.
Locate and correct wiring fault and go to
Test 8.
Open circuit
532 to 588 Ohms
Go to Test 5.
Faulty
Replace sensor and go to Test 8.
OK
Go to Test 8.
Clean / replace toothed wheel, go to Test
8.
Faulty
OK
Done
Fault still present
Contact Cannondale Dealer Service.
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
56
COMPONENT TESTING (NON-EFI)
Test for continuity between both black wires; there
should be continuity.
BATTERY
Test for continuity between both red wires; there
should be continuity.
1. Filling electrolyte properly, Charging (times and
rates).
Test for short circuit between one of the red wires
and the two blacks; there should be no continuity.
Repeat the test for the other red wire. There
should be no continuity.
2. Load testing using a commercially available load
tester.
3. Installation
4. Test for continuity between both black output
wires and the rectifier/regulator housing. There
should be no continuity.
5. Connect the positive multi meter probe to the red
output wire of the rectifier/regulator. Connect the
black multi meter to the yellow input wire. Repeat
this procedure for each wire.
Washers?
Loctite
Torque
If an OL (no continuity) is indicated in all three yellow wires, go to the next step.
RECTIFIER /REGULATOR
NOTE :
If vehicle is equipped with single phase rectifier/
regulator, complete the steps described, but omit
the references made to the third wire (three phase
rectifier/regulator).
If you have continuity on any of the three yellow
wires, replace the rectifier/regulator with a new
one.
6. Connect the negative multi meter probe to the red
output wire of the rectifier/regulator. Connect the
positive probe to a yellow input wire. Check the
reading. Repeat the test for each wire.
If a reading around 1 to 1.5 Ohms is obtained on
all wires, go to the next step.
Dynamic Test
1. Set multi-meter to DCV or Vdc (DC volts); switch
the range to 20 or 50V. Connect the multi meter
leads to the battery terminals. Start and rev the
engine up to 3000 r/min. Check the battery
voltage.
If the voltage is higher than 13.5V, rev the engine
to 5000 r/min. Check the reading on the meter, if it
is lower than 14.8V, the charging system is OK.
If the voltage at 3000 r/min. is lower than 13.5V,
go to the static test.
If an OL (no continuity) is obtained on any wire,
replace the rectifier/regulator with a new one.
7. Connect the negative multi meter probe to the
negative output wire of the rectifier/regulator.
Connect the positive multi meter probe to one yellow wire. Check the reading. Repeat for all yellow
wires.
If an OL (no continuity) is on all three wires is
obtained, go to the next step.
If you have continuity on any wire, replace the
rectifier/regulator with a new one.
Static Test
1. Disconnect the rectifier/regulator from the vehicle
wiring harness.
2. Switch the multi meter to Ohms (lowest range).
3. If the rectifier regulator has two red output wires
and two black output wires:
57
8. Connect the positive multi meter probe to the negative output wire of the rectifier/regulator. Connect
the negative multi meter probe to one yellow wire
and check the reading. Repeat for the other two
yellow wires.
If a reading around 1 to 1.5 Ohms is obtained on
all three tests, the rectifier/regulator is OK.
8/14/02
If an OL (no continuity) is obtained on any one of
the three tests, replace the rectifier/regulator.
Stator
NOTE :
If vehicle is equipped with a single phase stator,
complete the steps described, but omit the
references made to the third wire (three phase
stator).
Static Test
1. Disconnect the stator connector.
2. Set multi meter to the lowest Ohms setting.
Measure the resistance between all three wires
coming from the stator. Start with one wire and
read resistance between it and the other two.
Repeat for remaining two wires.
If all readings are within 0.5 to 2.0 Ohms, go to
the next step.
exist in the rectifier/regulator. Test the rectifier/
regulator.
FLYWHEEL
Inspection Points
1. Check for contact between the installed flywheel
and crankshaft position sensor. Make sure the
specified sensor air gap is maintained throughout
flywheel rotation.
SERVICE:
1. Inspect the flywheel for cracking, damaged
magnetic material, key groove, and woodruff
(crankshaft) key.
2. Check flywheel key location. Make sure the hub
has not spun in the aluminum body. The key “cut”
in the hub should be aligned with the “C” in the
molded “Cannondale” text.
START BUTTON (ATV & MOTORCYCLE)
If one of the readings is lower than 0.5 Ohms or
higher than 2.0 Ohms, replace the stator.
Connect one of the multi meter leads up to one of
the three yellow wires. Connect the other multi
meter lead up to the crankcase or to a grounding
point on stator core if it has been removed. Check
the reading on the meter. Make sure the connection of the lead to the crankcase or stator core is a
good one.
1. Disconnect the engine start button from the main
harness.
2. Test for continuity between the two leads. There
should be no continuity.
3. Press and hold the button and test for continuity.
There should be continuity when the button is
pressed.
No reading or “OL” displayed, go to the next step.
If you have any reading between 100 Ohms and
zero Ohms, replace the stator.
Dynamic Test - AC Output
1. Switch the multi meter to the AC voltage (range at
least 100 VAC). Make sure you do not switch to
DCV or Vdc by mistake. Connect the multi meter
leads between two of the yellow wires emerging
from the stator. Start the engine and bring to 5000
r/min. Check the reading on the meter. Switch one
of the multi meter leads to another yellow wire
and check the reading again.
ENGINE STOP BUTTON
1. Disconnect the engine stop button from the main
harness.
2. Test for continuity between the two leads. There
should be continuity.
3. Press and hold the button and test for continuity.
There should be no continuity when the button is
pressed.
If three equal readings are obtained, all higher
than 50 VAC, the stator is ok. A problem may
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
58
ENGINE STOP SWITCH (ATV)
STARTER SOLENOID
1. Disconnect the engine stop switch from the main
harness.
Dynamic Test - Solenoid Function
2. Slide the switch to the RUN position. There
should be continuity between the two switch
leads.
1. Press the engine start button. On ATVs, the
additional step of turning the ignition key ON and
pulling in the clutch lever is required before
pressing the start button.
3. Slide the switch to the OFF position. There should
be no continuity.
The solenoid is normal if the solenoid clicks when
the start button is pressed.
If you do not hear a “CLICK”, go to the next test.
CLUTCH LEVER SWITCH (ATV)
Static Test - Harness Voltage
1. Disconnect the clutch switch connector from the
switch body.
1. Disconnect the solenoid from the main wiring
harness.
2. Test for continuity between the switch terminals.
There should be no continuity.
2. On ATVs, turn the ignition key ON and pull in the
clutch lever.
3. Pull in the clutch lever and test for continuity
between the switch terminals. There should be
continuity.
Set multi meter to DCV 20V range and connect
the positive meter lead to connector pin A; connect the negative meter lead to connector pin B.
Press the engine start button. The reading should
be same as battery voltage (12.5 to 13.0Vdc).
KEY SWITCH
If no voltage is detected, check the main fuse.
1. Disconnect the key switch connectors from the
main harness.
2. Rotate the key to the OFF position.
Set the multi meter to Ohms. Test for continuity
between any of the switch leads. There should be
no continuity between any of the leads.
3. Rotate the key to the ON position. There should
be continuity between the green and violet leads.
There should be no continuity between the yellow
lead and the green or violet.
Rotate the switch to the “ON w/ Lights” position.
There should be continuity between all leads.
If the main fuse is OK, check the starting circuit
for an open or short circuit. Take corrective action.
Consult the vehicle wiring diagram.
3. Set multi meter to Ohms. Connect the positive
meter lead to solenoid connector harness pin B
and the negative meter lead to ground. There
should be continuity.
If an open circuit is detected, consult the vehicle
wiring diagram.
Static Test - Resistance
1. Disconnect the solenoid from the main wiring
harness.
2. Measure the resistance of the solenoid coil at the
harness connector.
GREEN VIOLET YELLOW
OFF
SERVICE:
RUN
Solenoid coil resistance
5.0 Ohm
RUN W/LTS
59
8/14/02
Operation Test
harness starting circuits for short or open circuits.
Consult the vehicle wiring diagram.
1. Disconnect the solenoid from the main wiring
harness.
If the starter motor does not turn, confirm that the
engine can be turned over manually. If the engine
does not turn over manually, there is a internal
engine problem. Take corrective action.
2. Connect the positive lead of a 12V battery power
source to the solenoid coil positive lead or terminal (pin A) and the negative lead of the 12V battery power source to the solenoid coil negative
lead or terminal (pin B).
There should be continuity between the large terminals while the battery source is connected, and
no continuity when the battery source is disconnected.
STARTER MOTOR
Press the engine start button. On ATVs, the additional step of turning the ignition key ON and pulling
in the clutch lever is required before pressing the
start button.
If the engine turns over manually, the starter is
damaged; replace it.
FUSES
When a fuse blows repeatedly, it usually indicates a
short circuit or current overload in the electrical
system. The problem could be intermittent or constant.
1. To inspect the fuse, remove the fuse from the
holder and inspect it.
The starter motor is normal if the engine turns over
when the start button is pressed.
(1)
REPLACE
If the engine does not turn over:
- Check for loose battery cables or open circuit in
battery cables.
- Check for loose solenoid terminals or connectors
- Test the solenoid operation
3. Disconnect the positive cable from the positive
starter terminal. Press the engine start button. On
ATVs, the additional step of turning the ignition
key ON and pulling in the clutch lever is required
before pressing the start button. Test for 12V (+)
voltage between the starter cable and ground.
There should be 12V (+) when the button is
pressed.
WARNING
If no voltage is found and the solenoid is OK,
check the vehicle wiring harness starting circuits
for short or open circuits. Consult the vehicle wiring diagram.
Use only specified fuse rating. An electrical fire or vehicle damaged can result if a
fuse rating other than specified is used.
Using other materials in place of the fuse
will cause damage to system.
If voltage is present, go to next step.
4. Connect the starter motor positive terminal
directly to the vehicle battery positive terminal
with a heavy lead similar in size to starter motor
harness cable.
If the starter motor turns, check the vehicle wiring
Electrical_EFI Service Manual.fm
© 2002 Cannondale Corporation - All Rights Reserved
60
Starter Solenoid - - - - - - - - - - - - - - - - - 59
Starter Motor - - - - - - - - - - - - - - - - - - - 60
Fuses - - - - - - - - - - - - - - - - - - - - - - 60
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - 3
Important Notice - - - - - - - - - - - - - - - - - - 3
About the manual - - - - - - - - - - - - - - - - - 3
Comments? - - - - - - - - - - - - - - - - - - - - 3
IMPORTANT MANUAL INFORMATION- - - - - - - - - - - 4
ENGINE MANAGEMENT SYSTEM (EMS) - - - - - - - - - 6
Engine Control Unit (ECU) - - - - - ECU Programming - - - - - - - - - Servicing connectors and couplers - Barometric pressure sensor - - - - Throttle position sensor (TPS) - - - Coolant temperature sensor - - - - Air temperature sensor - - - - - - - Crankshaft position sensor - - - - - Idle Air Control Valve (IACV) - - - - Ignition coil- - - - - - - - - - - - - EMS Power Relay - - - - - - - - - Fuel pump and fuel pressure regulator
Cooling Fan (ATV - - - - - - - - - -
-
-
-
-
-
-
- 6
- 7
- 9
10
10
12
12
13
14
15
15
17
20
CANNONDALE DIAGNOSTIC AND MAINTENANCE TOOL
VERSION 2.0 - - - - - - - - - - - - - - - - - - - - - - - 21
General Information - - - - - - - - - - - - - - - 21
Installation - - - - - - - - - - - - - - - - - - - - 21
In the Windows Explorer, double click the SecurityCode
application. Or, you can access this application by clicking
on Security code.exe through the program group. - - 22
Common Problems- - - - - - - - - - - - - - - - 23
Interpreting Error Messages - - - - - - - - - - - 24
Other Messages - - - - - - - - - - - - - - - - - 25
Communication cable - - - - - - - - - - - - - - 27
Cannondale Diagnostic and Maintenance tool Main Window - - - - - - - - - - - - - - - - - - - - - - - - 28
ECU Operating code - - - - - - - - - - - - - - - 29
Calibrations - - - - - - - - - - - - - - - - - - - 37
ECU Monitor - - - - - - - - - - - - - - - - - - - 39
Reading Fault Codes - - - - - - - - - - - - - - - 40
FAULT TROUBLESHOOTING - - - - - - - - - - - - - - 42
Sensor Supply Voltage - - - System Voltage - - - - - - Fuel Pump - - - - - - - - - Ignition Coil - - - - - - - - Cooling Fan (ATV Only) - - Fuel Injectors - - - - - - - Throttle Position Sensor (TPS)
Air temperature Sensor - - - Coolant Sensor - - - - - - Idle Air Control Valve (IACV) Crankshaft Position Sensor- -
-
-
-
-
-
-
-
-
-
-
42
43
44
45
46
47
50
51
53
55
56
COMPONENT TESTING (NON-EFI)- - - - - - - - - - - - 57
Battery - - - - - - - - - - - - Rectifier /Regulator - - - - - - Flywheel - - - - - - - - - - - Start Button (ATV & Motorcycle)
Engine Stop Button- - - - - - Engine Stop Switch (ATV) - - Clutch Lever Switch (ATV) - - Key Switch - - - - - - - - - - -
-
-
-
-
-
-
-
-
-
57
57
58
58
58
59
59
59
1
5002066
Printed : 8/14/02